Composition for dust control

ABSTRACT

The invention is directed towards methods and compositions for preventing dusting problems in mineral supplement. The method involves treating the mineral supplement or a dust releasing material with a composition comprising polymerized organic acid.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention relates generally to one or more methods,compositions of matter, and or apparatuses useful in suppressing dustreleases such as those from mineral supplement material.

Mineral supplements, like many hard crystalline materials tend tocontain fines or to be friable and form fines, and these fines can be adust releasing nuisance and therefore require dust control. These dustnuisances can create significant health, environmental, and safetyproblems.

Dust control methods are practiced in many industries handling suchsolids. For example, during the production of dry granular fertilizercertain mechanical conveyance steps may generate small particles offertilizer that can be transported to undesirable locations by stray aircurrents. Worse, if the particle size is small enough the dust canremain suspended in the air for extended periods of time exacerbatingthese problems. As a result, a number of dust control technologies havebeen developed.

In addition, the properties and end uses of mineral supplement furthercomplicate this situation. Because mineral supplements are directlyapplied in open environments to plant life and those plants in turn maybe consumed by animals or humans, many effective dust control agentsmust also be non-toxic. Therefore, it is important that theenvironmental and dietary safety of additives should be considered. Inaddition dust control agents may not interact with the mineralsupplement in any manner which would impair the benefit of the mineralsupplement to the plant such as detrimentally changing pH or any otherchemical property. Another category of chemicals used in dust controlare asphaltenes or heavy petroleum based materials; unfortunatelybecause they contain aromatics and because of other purity issuesadditives including them often pose health and environmental problems.Also many of these compositions can require cumbersome and dangerousheating systems just prior to their application.

As a result there is ongoing need and clear utility in a novel improvedmethod and/or composition and/or apparatus for reducing dust releasefrom mineral supplement. The art described in this section is notintended to constitute an admission that any patent, publication orother information referred to herein is “Prior Art” with respect to thisinvention, unless specifically designated as such. In addition, thissection should not be construed to mean that a search has been made orthat no other pertinent information as defined in 37 CFR. §1.56(a)exists.

BRIEF SUMMARY OF THE INVENTION

At least one embodiment of the invention is directed towards a method ofreducing the release of dust from a mass prone to release dust. Themethod comprises the step of: contacting the mass with a compositioncomprising a polymerized organic acid.

The polymerized organic acid may be constructed from monomers selectedform the list consisting of hydroxy fatty acids such as: ricinoleicacid, 12-hydroxystearic acid, and any combination thereof. Thepolymerized organic acid may be a copolymer which also comprisesglycerol repeating units, the glycerol repeating units being one ofmonoglycerol, diglycerol, triglycerol, and any combination thereof. Thepolymerized organic acid may be a block copolymer comprising a firstchain consisting essentially of repeating polymerized organic acidrepeating units and a second chain consisting essentially of repeatingglycerol units, the first chain and the second chain being linked by anester bond. The first chain may have an n value of more than 2. Thepolymerized organic acid may be a block copolymer comprising a firstchain consisting essentially of repeating ricinoleic acid repeatingunits and a second chain consisting essentially of repeating glycerolunits, the first chain and the second chain being linked by an esterbond. This block copolymer may have a first chain with an n value ofmore than 100.

The polymerized organic acid may also comprise alkoxy groups (such asethoxy or propoxy) or repeating units thereof. The composition may beapplied as a liquid, foam, dispersion, or an emulsion. The mass may beprone to release dust is an aggregation of mineral supplement, minedmaterials, synthesized dry materials, fertilizer, coal, wood chips,agricultural products, fruit, aggregates, fine materials, potash,phosphate, road dust, and any combination thereof. After the mass hasbeen treated, the mass may be prone to release dust but will have areduction in released dust that will persist indefinitely (possiblyessentially permanently).

DETAILED DESCRIPTION OF THE INVENTION

The following definitions are provided to determine how terms used inthis application, and in particular how the claims, are to be construed.The organization of the definitions is for convenience only and is notintended to limit any of the definitions to any particular category.

“Mineral Supplement” means a composition of matter characterized asbeing predominantly made up of materials which function as a form ofanimal feed and/or dietary supplement and/or nutritional supplement forconsumption by an animal and/or which functions as a fertilizer forplants. Fertilizers are predominantly made up of inorganic substances,primarily salts and are in a form which increases the nutrients absorbedby plants. Fertilizers greatly affect the soil (its physical, chemical,and biologic properties) and plants. In soil, fertilizers undergovarious changes that influence the solubility of their nutrients, theirpermeability, and their availability to plants. Fertilizers includedirect plant nutrients (N, P, K, Mg, B, Cu, Mn) such as nitrogenfertilizers (ammonium, sodium, and calcium nitrates; ammonium sulfate;urea), phosphorus-supplying fertilizers (superphosphate, ground rockphosphate, ammonium and calcium phosphates), potassium fertilizers(potassium chloride, 30 and 40 percent potassium salt, potassiumsulfates, potassium nitrate), and micronutrient fertilizers. Indirectfertilizers improve the agrochemical and physiochemical properties ofsoil and activate nutrients (for example, lime fertilizers and gypsum).

“Ricinoleic Acid” means a composition of matter which is an organic acidand may be according to the formula (as well as any steroechemicalisomers thereof) of:

“Polyricinoleic Acid” means a composition of matter which ischaracterized as being a polymer comprising a number of ricinoleic acidrepeating units linked by ester bonds between the hydroxyl group alongthe fatty chain and the proton donating acid oxygen, the repeating unitsmay be according to the formula (as well as any steroechemical isomersthereof) of:

wherein n is the n value which is a number greater than 1.

“Polymerized Organic Acid” means a composition of matter characterizedas being a polymer comprising ester linked repeating units in which therepeating units have a C4-C100 fatty chain along which are both at leastone hydroxyl group and at least one end of at least one of thecarboxylic acid group.

“Fatty Chain” means a portion of a repeating unit characterized as beinga series of bonded carbon atoms in one or more arrangements selectedfrom: alkyl, straight chain alkyl, branched alkyl, aryl, cyclo, phenyl,benzyl, cyclic, dendritic, and any combination thereof.

In the event that the above definitions or a description statedelsewhere in this application is inconsistent with a meaning (explicitor implicit) which is commonly used, in a dictionary, or stated in asource incorporated by reference into this application, the applicationand the claim terms in particular are understood to be construedaccording to the definition or description in this application, and notaccording to the common definition, dictionary definition, or thedefinition that was incorporated by reference. In light of the above, inthe event that a term can only be understood if it is construed by adictionary, if the term is defined by the Kirk-Othmer Encyclopedia ofChemical Technology, 5th Edition, (2005), (Published by Wiley, John &Sons, Inc.) this definition shall control how the term is to be definedin the claims.

In at least one embodiment of the invention a composition of matter isadded to a mineral supplement material and/or a material prone torelease dust. The composition comprises a polymerized organic acid. Theapplication of the composition reduces the tendency of the mineralsupplement material to release dust. In at least one embodiment thecomposition is applied to the material as a liquid. In at least oneembodiment the composition is applied to the material as foam. In atleast one embodiment the composition is applied to the material asdispersion. In at least one embodiment the composition is applied to thematerial as an emulsion.

Mineral supplement granules produce large amounts of fugitive dust. Thisis because ultra-fine mineral supplement particles are so light thatthey can be suspended and travel aloft when contacted by moving air.Mineral supplement commonly becomes ultra-fine due to excessive grindingor due to attrition of the delicate mineral supplement masses duringprocessing or handling.

The effectiveness of the invention was quite surprising and in light ofthe teachings of the prior art the invention displays unexpectedresults.

In at least one embodiment the polymerized organic acid comprisesrepeating units of organic acids containing one or more hydroxylfunctional groups selected from the list consisting of: ricinoleic acid,12-hydroxystearic acid, and any combination thereof.

Fatty acids able to form polymerized fatty acids as defined above haveto have at least one hydroxyl group in the carbon chain. Arepresentative list of suitable hydroxy group bearing fatty acids can befound are listed on the website:http://www.lipidmaps.org/data/structure/LMSDSearch.php?Mode=ProcessClassSearch&LMID=LMFA0105&s=hydroxyfatty acids. (As accessed on Nov. 8, 2013)

In at least one embodiment the polymerized organic acid also comprisesglycerol repeating units and can therefore also be considered a speciesof polyglycerol.

In at least one embodiment the polymerized organic acid also comprisesalkoxy groups (such as ethoxy or propoxy) or repeating units thereof.

Without being limited by a particular theory or design of the inventionor of the scope afforded in construing the claims, it is believed thatthe particular structure of the polymer is what affords the compositionit unexpectedly high effectiveness as a dust control agent. Polymerizedorganic acids have large numbers of moderately polar ester bondsembedded within largely non-polar fatty region of the polymer. Thisallows for the formation of unique surface-surface interactions betweenthe polymerized organic acid and the particulate matter. In additionthey have just the right molecular weight to induce the formation ofagglomerations that are massive and therefore resistant to airbornedispersal.

Polymerized organic acids may be produced from oleochemicals.Oleochemicals are chemicals derived from plant and animal fats. Mostplant and animal oils are glycerides of mixtures of fatty acids. Aglyceride is the reaction product of a carboxylic acid and glycerol.Often oleochemicals are formed by taking natural substances like fattyacids, fatty acid methyl esters (FAME), fatty alcohols, fatty amines andglycerols and performing various chemical and enzymatic reactions suchas hydrolysis, and/or transesterification.

As described in the Trade Sheet “Production and Uses of Key Castor OilOleochemicals”, Oleochemicals have been used for quite some time invarious industries as lubricants, caulks, sealants, paint binders,adhesives, anti-static agents, and varnishes. As described inInternational Patent Application WO 2006068627 they have been used as ananti-caking agent in rubber manufacturing. They however have not beenpolymerized and then used as dust control agents for mineralsupplements.

Japanese Patents Publication JP 2011094007 discloses a dust controlagent containing water-swellable particles which includes apoly(ricinoleic acid)-polyoxyethylene block copolymer. In at least oneembodiment the polymerized organic acid excludes the presence ofoxyethylene monomers. In at least one embodiment the polymerized organicacid is a homopolymer and excludes the presence of copolymers and/orheteropolymers.

U.S. Pat. No. 5,443,846 describes the use of poly(ricinoleic acid) as abinder in a delayed release drug. This however is the opposite of theuse in the invention because it is not used to delay release but to bindthe mineral supplements indefinitely. In at least one embodiment thepolymerized organic acid is so dosed as to not allow for the timedrelease of the treated material.

In at least one embodiment the polymerized organic acid has an n valueof between 1 and 1000 (or higher). In at least one embodiment thepolymerized organic acid has a molecular weight of between 1000 (orlower) and 1,000,000 Dalton (or higher).

Materials prone to release dust to which the polymerized organic acidmay be applied include but are not limited to mined materials,synthesized dry materials, fertilizer, coal, wood chips, agriculturalproducts, fruit, aggregates, fine materials, potash, phosphate, roaddust, and any combination thereof.

In at least one embodiment the polymerized organic acid is usedaccording to the methods and/or alongside the compositions for dustcontrol described in U.S. patent application Ser. Nos. 12/356,352 and13/826,385.

EXAMPLES

The foregoing may be better understood by reference to the followingexamples, which is presented for purposes of illustration and is notintended to limit the scope of the invention.

Laboratory analyses were conducted on samples of monoammonium phosphatewhich is a material prone to releasing fugitive dust. The monoammoniumphosphate was treated with various polymerized organic acids as well asother materials for comparison. Table illustrates the results.

TABLE 1 Fugitive % Dust TEST Dust (ppm) Reduction Test #1 Untreated 5830 0% Polyricinoleic acid 4 lb/ton 889 85% Polyricinoleic acidpolyglycerol copolymer 810 86% 4 lb/ton Test #2 Untreated 3785  0%Polyricinoleic acid 4 lb/ton 342 91% Polyricinoleic acid polyglycerolcopolymer 382 90% 4 lb/ton Heavy Petroleum 4 lb/ton 374 90% Test #3Untreated 6144  0% Polyricinoleic acid 4 lb/ton 1117 81% Polymerizedlinseed oil resin 4 lb/ton 3797 38% Test #4 Untreated 4711  0%Poly(12-hydroxystearic acid) 4 lb/ton 856 82%The reduction in fugitive dust levels demonstrated the efficacy ofvarious additives. Compared to a heavy petroleum based coating, thematerials disclosed herein provided equal or better dust controlperformance while eliminating the use of petroleum derived materials.Compared to a polymerized linseed oil resin, polyricinoleic acidprovided significantly improved fugitive dust control.

While this invention may be embodied in many different forms, theredescribed in detail herein specific preferred embodiments of theinvention. The present disclosure is an exemplification of theprinciples of the invention and is not intended to limit the inventionto the particular embodiments illustrated. All patents, patentapplications, scientific papers, and any other referenced materialsmentioned herein are incorporated by reference in their entirety.Furthermore, the invention encompasses any possible combination of someor all of the various embodiments described herein and/or incorporatedherein. In addition the invention encompasses any possible combinationthat also specifically excludes any one or more of the variousembodiments described herein and/or incorporated herein.

The above disclosure is intended to be illustrative and not exhaustive.This description will suggest many variations and alternatives to one ofordinary skill in this art. The compositions and methods disclosedherein may comprise, consist of or consist essentially of the listedcomponents, or steps. As used herein the term “comprising” means“including, but not limited to”. As used herein the term “consistingessentially of” refers to a composition or method that includes thedisclosed components or steps, and any other components or steps that donot materially affect the novel and basic characteristics of thecompositions or methods. For example, compositions that consistessentially of listed ingredients do not contain additional ingredientsthat would affect the properties of those compositions. Those familiarwith the art may recognize other equivalents to the specific embodimentsdescribed herein which equivalents are also intended to be encompassedby the claims.

All ranges and parameters disclosed herein are understood to encompassany and all subranges subsumed therein, and every number between theendpoints. For example, a stated range of“1 to 10” should be consideredto include any and all subranges between (and inclusive of) the minimumvalue of 1 and the maximum value of 10; that is, all subranges beginningwith a minimum value of 1 or more, (e.g. 1 to 6.1), and ending with amaximum value of 10 or less, (e.g. 2.3 to 9.4, 3 to 8, 4 to 7), andfinally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 containedwithin the range.

All numeric values are herein assumed to be modified by the term“about,” whether or not explicitly indicated. The term “about” generallyrefers to a range of numbers that one of skill in the art would considerequivalent to the recited value (i.e., having the same function orresult). In many instances, the term “about” may include numbers thatare rounded to the nearest significant figure. Weight percent, percentby weight, % by weight, wt %, and the like are synonyms that refer tothe concentration of a substance as the weight of that substance dividedby the weight of the composition and multiplied by 100. Percentages andratios are by weight unless otherwise so stated.

As used in this specification and the appended claims, the singularforms “a,” “an,” and “the” include plural referents unless the contentclearly dictates otherwise. Thus, for example, reference to acomposition containing “a compound” includes a mixture of two or morecompounds. As used in this specification and the appended claims, theterm “or” is generally employed in its sense including “and/or” unlessthe content clearly dictates otherwise. All chemical structures providedin this application contemplate and include every possible stereoisomers, conformational isomers, rotational isomers, and chiralalternative of the specific illustrated structure.

This completes the description of the preferred and alternateembodiments of the invention. Those skilled in the art may recognizeother equivalents to the specific embodiment described herein whichequivalents are intended to be encompassed by the claims attachedhereto.

What is claimed is:
 1. A method of reducing the release of dust from amass prone to release dust, the method comprising the step of:contacting the mass with a composition comprising a polymerized organicacid which comprise alkoxy groups, wherein the polymerized organic acidis a copolymer which comprises glycerol repeating units.
 2. The methodof claim 1 in which the polymerized organic acid is constructed frommonomers selected from the list consisting of hydroxy fatty acids suchas: ricinoleic acid, 12-hydroxystearic acid, and any combinationthereof.
 3. The method of claim 1, the glycerol repeating units beingone of: monoglycerols, diglycerols, triglycerols, and any combinationthereof.
 4. The method of claim 1, the polymerized organic acid being ablock copolymer comprising a first chain consisting essentially ofrepeating polymerized organic acid repeating units and a second chainconsisting essentially of repeating glycerol units, the first chain andthe second chain being linked by an ester bond.
 5. The method of claim 4in which the average number of repeating units is more than
 2. 6. Themethod of claim 1 in which the polymerized organic acid is a blockcopolymer comprising a first chain consisting essentially of repeatingricinoleic acid repeating units and a second chain consistingessentially of repeating glycerol units, the first chain and the secondchain being linked by an ester bond.
 7. The method of claim 4 in whichthe first chain has an average number of repeating units of more than100.
 8. The method of claim 1 in which the alkoxy groups comprise ethoxyor propoxy groups.
 9. The method of claim 1 in which the composition isapplied as one or more selected from the list consisting of: foam,dispersion, emulsion, and any combination thereof.
 10. The method ofclaim 1 in which the mass prone to release dust is an aggregation ofmineral supplement, mined materials, synthesized dry materials,fertilizer, coal, wood chips, agricultural products, fruit, aggregates,fine materials, potash, phosphate, road dust, and any combinationthereof.
 11. The method of claim 1 in which after it has been treated,the mass prone to release dust will have a reduction in released dustthat will persist indefinitely.
 12. A method of reducing the release ofdust from a mass prone to release dust, the method comprising the stepof: contacting the mass with a composition comprising a polymerizedricinoleic acid wherein the composition comprises glycerol repeatingunits and better dust control effects than a comparable amount ofpetroleum.